Industrial Automation: Architecture

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Automation

Automation
Automation is a set of technologies enabling the operation of machines and systems with minimal
human intervention, achieving performance levels superior to manual operation.

"Automation" originates from the Greek words “Auto" (self) and “Matos" (moving) ⇒
systems that move by themselves
Automation refers to a technology that employs mechanical, electronic, and computer
systems to handle processes and control manufacturing operations
Automation began when machines started replacing labor-intensive tasks performed by
workers
Humans have introduced robotics, CAD/CAM, flexible manufacturing systems, and other
innovations to enhance quality of life and industrial productivity

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Advantages of Automation

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Advantages of Automation

Certain operations demand automation due to their precision, miniaturization, or geometric

complexity, which are unattainable manually
Integrated circuit fabrication
Rapid prototyping using CAD models
Machining of complex, mathematically defined surfaces using CNC systems

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Disadvantages of Automation

Disadvantages of Automation: High Start-Up and Operational Costs, Expensive Maintenance,

Obsolescence and Depreciation Costs, Unemployment, Not Economically Viable for Small-Scale
Production

Obsolescence and Depreciation Costs

This is the gradual reduction in the value of equipment and machinery, often due to technological
advancements. Depreciation can be categorized as:
Physical Depreciation: Results from physical damage, wear, or corrosion of equipment
Functional Depreciation: Arises when equipment becomes outdated or unable to meet new
service demands, often due to the discovery of superior technologies

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History of Industrial Automation

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History of Industrial Automation

First Industrial Revolution

The invention of the steam engine and self-driven machines in the 17th century led to early
automatic control systems like speed controllers, temperature regulators, and pressure monitors

Second Industrial Revolution

Characterized by the widespread use of electricity, telegraph networks, and railroads, this era
brought a significant boost in productivity and economic growth

Digital Revolution
This period marked the transition from mechanical and analog systems to digital technologies.
Key advancements included microprocessors, integrated circuits, and innovations in computing
and communication, such as mobile telephony and the Internet

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History of Industrial Automation

Industry 4.0
This phase introduced AI, robotics, IoT, machine-to-machine (M2M) communication, and smart
automation. It is defined by interconnected systems and advanced automation technologies

Industry 5.0
Focusing on the synergy between technology and human talent, this vision emphasizes
sustainability, resilience, and human-centric solutions. Robots, AI, IoT, and Big Data remain
integral, but the emphasis shifts toward intelligent, efficient, and environmentally friendly systems.

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Fixed Automation

Fixed Automation
Fixed automation systems have a pre-determined sequence of processing or assembly operations
configured by the equipment. These systems are best suited for high-volume production where
the initial high equipment costs can be justified by economies of scale.

High production rates

Significant initial investment in equipment
Limited flexibility to accommodate product changes
Examples: Machining transfer lines, Automated assembly machines, Distillation processes,
Conveyors, Paint shops

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Programmable Automation

Programmable Automation
Programmable automation is designed to accommodate different product configurations by
changing the sequence of operations. The process sequence is controlled by a program, which can
be modified or replaced to produce different products.

Suitable for batch production and low-to-medium job variety.

Moderate flexibility compared to fixed automation.
Ideal for medium-to-high product volumes.
Examples: Numerically Controlled (NC) machine tools, Industrial robots, Programmable Logic
Controllers (PLCs), Steel rolling mills, Paper mills

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Flexible Automation

Flexible Automation
Flexible automation is typically used in Flexible Manufacturing Systems (FMS) and relies heavily
on computer control. High-level commands, such as product type and sequence, are entered into
a computer, which then automatically manages machine settings, tool changes, and product
transfers.

High flexibility to adapt to product variations

Reduced downtime for tool and product changes
Automated material handling and product routing
Examples: Multi-purpose CNC machines, Automated Guided Vehicles (AGVs)

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Types of Automation Relative to Production Quantity and Product Variety

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Integrated Automation

Integrated Automation
Integrated automation represents the complete automation of a manufacturing plant, where all
processes operate under computer control, and coordination occurs through digital information
systems.

Centralized control of tools and processes.

Full integration of process and management operations.
Minimal human intervention.
Utilizes a common database for business and manufacturing integration.
Examples: Advanced Process Automation Systems, Computer Integrated Manufacturing (CIM)

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Integrated Architecture

Integrated Architecture
Integrated Architecture is a unified control and information system that provides one control
platform, a standard design framework, interoperable, secure connectivity, visualization tools and
smart devices across disciplines.

It can be scaled from a single machine or across multiple lines and facilities to achieve
strategic business objectives, such as achieving lower total cost of ownership and improving
workplace efficiency.

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Basic Components of an Automated System

An automated system consists of three fundamental elements:

1 Power: To accomplish the process and operate the system.
2 Program of Instructions: To direct the process.
3 Control System: To actuate the instructions.

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Power for the Process

Power is essential for both the operation of the process and the controls in an automated system.
The primary source of power is typically electricity.

Key Components Utilizing Power

Controller Unit: Modern industrial controllers are digital computer-based and require
electrical power to read the program instructions, perform control calculations, and execute
commands.
Actuators: Commands from the controller are carried out using electromechanical devices
like switches and motors, Low-voltage control signals are amplified to provide the appropriate
power for the actuating devices.
Data Acquisition and Information Processing: Data from the process is collected and used as
input for control algorithms, Record-keeping functions for process performance or product
quality require modest power.

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Program of Instructions

The program of instructions defines the actions performed by the automated process. It specifies
each step and its associated parameters.

Types of Programs
Work Cycle Programs (Simple Processes): In basic processes, the work cycle involves
maintaining a single process parameter, such as the temperature of a furnace, at a set level
for a defined duration. For example, setting the furnace temperature dial determines the
process. Adjusting the program involves changing this setting. More advanced systems might
control multiple parameters, like temperature and atmosphere simultaneously.
Work Cycle Programs (Complex Systems): Complex systems involve multiple steps that
repeat consistently without variation. Example sequence of steps: (1) Load the part into the
machine, (2) Perform the process (3) Unload the part.

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Basic Elements of An Automated System

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On-Premise vs. Cloud Systems in Industrial Automation

Even though cloud and on-premise systems fundamentally have only one difference-the
deployment approach, or, in simpler terms, where the industrial automation software is
located-this is a big enough factor to play a role in the overall success of an organization’s
automation strategy.

On-Premise Systems:
Industrial automation software is installed and hosted on the local servers of the organization that
uses it.

Cloud Systems:
Industrial automation software is hosted and run on the servers of the automation solution
provider.

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Cloud Automation Systems

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